VW Sharan Diesel Rattles with Failing Exhaust Flap

Had a similar issue with my 2005 VW Touran diesel about a year ago. As someone with moderate experience working on cars, I first noticed the same symptoms, loud cold starts and overall increased exhaust noise. Took it to my regular workshop where they diagnosed a defective exhaust flap. The flap motor had seized up, causing the valve to stay in one position. These exhaust valves are meant to regulate flow and noise levels, so when they fail, you get those exact symptoms youre describing. The repair involved replacing the complete flap motor assembly and recalibrating the exhaust components. Total cost was 190€ including parts and labor. Since the fix, the exhaust noise returned to normal levels and cold starts are much quieter. Before suggesting specific solutions, could you share: Current mileage on your Sharan? Which error codes are you getting exactly? Have you noticed any changes in engine performance? Is the check engine light constantly on or intermittent? This information would help determine if youre dealing with the same exhaust repair issue I had or if theres something else going on.

Just had the car in for service last month. The exhaust noise started shortly after. When I scan for codes, I get P2432 and P2433, which point to exhaust flap issues. The engine performance seems normal, but the exhaust sounds like a sports car, especially during cold starts. The check engine light comes on intermittently, usually after longer drives. I checked the exhaust flaps manually and noticed resistance when trying to move them. Wondering if cleaning the flap motor might help before considering a full replacement. The exhaust blockage seems partial rather than complete since the car still runs fine. Has anyone tried cleaning the exhaust flap mechanism first? Would hate to spend money on new parts if a simple cleaning could fix it.

Based on my experience with the same issue on my Touran, I would advise against just cleaning the flap motor. I initially tried that approach too, but it only provided temporary relief. The exhaust noise came back within weeks, and the error codes P2432 and P2433 reappeared. The resistance you feel when moving the flaps manually is a classic sign of a failing flap motor. These exhaust valves are exposed to extreme temperatures and exhaust gases, which eventually cause the mechanism to seize. When the flap motor starts failing, it typically needs complete replacement rather than cleaning. The fact that your exhaust noise increased after a service is interesting, sometimes disturbing the exhaust system during maintenance can accelerate an already developing flap motor issue. The intermittent check engine light matches exactly what I experienced before getting the full repair done. The repair cost difference between attempting cleaning versus replacing the flap motor assembly was minimal in my case. A proper exhaust repair with new components will likely save you money in the long run and properly resolve those error codes. Want to share what quote your local workshop gave you for the exhaust flap replacement? The 190€ I paid seemed reasonable considering the specialized nature of the repair.

Thanks for the detailed feedback. This matches what my workshop quoted, around 200€ for a complete flap motor replacement. Given what you and others have shared, I think attempting to clean the exhaust components would just be delaying the inevitable. The consistent symptoms between our cases, the error codes, cold start noise, and that manual resistance in the exhaust flap, make it pretty clear what needs fixing. Going to book it in next week for the full repair to restore proper engine performance and get rid of that sports car sound. Really appreciate everyone sharing their repair experiences. Helps confirm Im not getting overcharged and that this is a known issue with a straightforward fix. Will update once the exhaust repair is done to let others know how it went.